Abstract: In machining, it is clearly noticed that the cutting tool wear influences the cutting process.
However, it is difficult with experimental methods to study the effects of tool wear on several
machining variables. Thus, in the literature, some earlier studies are performed separately
on the effect of tool flank wear and crater wear on cutting process variables (such as
cutting forces and temperature). Furthermore when the workpiece material adheres in cutting
tool, it affects considerably the heat transfer phenomena. Accordingly, in this work the
finite element analysis (FEA) is performed to investigate the influence of combination of
tool flank and crater wear on the local or global variables such as cutting forces, tool temperature,
chip formation on the one hand and the effects of the oxidized adhesion layer
considered as oxide (Fe2O3/Fe3O4/FeO) on the heat transfer in cutting insert on the other
hand. In this investigation, an uncoated cutting insert WC–6Co and medium carbon steel
grade AISI 1045 are used. The factorial experimental design technique with three parameters
(cutting speed Vc, flank wear land VB, crater wear depth KT) is used for the first investigation
without adhesion layer. Then, only linear investigation is performed. The analysis
has shown the influence of the different configurations of the tool wear geometry on the
local or global cutting process variables, mainly on temperature and cutting. The simulation’s
results show also, the highly influence of the oxidized adhesion layer (oxide Fe2O3/
Fe3O4/FeO) on the heat transfer.